Summary of Contents for TSI Instruments AeroTrak 9303
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® AeroTrak Handheld and Remote Airborne Particle Counters Models 9303, 7201/7301/7310/7501/7510, 7301-P Service Manual – Cleaning and Repair P/N 6007706, Revision F August 2022 Model 9303 Handheld Airborne Particle Counter Model 7301-P Remote Airborne Particle Counter Models 7201/7301/7310/7501/7510 Remote Airborne Particle Counters www.tsi.com...
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Start Seeing the Benefits of Registering Today! ® ® Thank you for your TSI instrument purchase. Occasionally, TSI releases information on software updates, product enhancements and new products. ® By registering your instrument, TSI will be able to send this important information to you.
Manual History ® The following is a manual history of the AeroTrak Handheld and Remote Airborne Particle Counters, Model 9303, Models 7201/7301/7310/7501/ 7510, Model 7301-P Service Manual (P/N 6007706). Revision Date March 2014 October 2014 April 2015 April 2016 May 2017 August 2022...
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returned under warranty to Seller's factory shall be at Buyer's risk of loss, and will be returned, if at all, at Seller's risk of loss. Buyer and all users are deemed to have accepted this LIMITATION OF WARRANTY AND LIABILITY, which contains the complete and exclusive limited warranty of Seller. This LIMITATION OF WARRANTY AND LIABILITY may not be amended, modified or its terms waived, except by writing signed by an Officer of Seller.
Contents Manual History ................... iii Warranty ...................... v Contents ....................vii Safety Information ..................ix Laser Safety ..................ix Labels ..................... x Description of Caution/Warning Symbols ..........xi Caution ....................xi Warning ....................xi Caution or Warning Symbols ............. xi Getting Help ..................
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Optics Block Cleaning ............... 4-16 Replacing the Laser Assembly ............4-19 Detector Board Replacement ............4-23 CHAPTER 5 Service Kits for Replacement Components ....5-1 CHAPTER 6 Troubleshooting ..............6-1 CHAPTER 7 Contacting Customer Service ........... 7-1 Technical Contacts ................7-1 International Contacts ..............
Safety Information This section gives instructions to promote safe and proper handling of the ® AeroTrak Handheld and Remote Airborne Particle Counters. I M P O R T A N T All maintenance and repair information in this manual is included for use by a qualified, factory-authorized, technician trained in the safe handling of laser and electrostatic sensitive components.
L a b e l s Advisory labels and identification labels are attached to the outside of the particle counter housing and to the optics housing on the inside of the instrument. 1. Serial number label (back panel) 2. Laser radiation label (internal) 3.
D e s c r i p t i o n o f C a u t i o n / W a r n i n g S y m b o l s Appropriate caution/warning statements are used throughout the manual and on the instrument that require you to take cautionary measures when working with the instrument.
G e t t i n g H e l p To obtain assistance with this product or to submit suggestions, please contact Customer Service: TSI Incorporated 500 Cardigan Road Shoreview, MN 55126 U.S.A. Fax: (651) 490-3824 (USA) Fax: 001 651 490 3824 (International) Telephone: 1-800-680-1220 (USA) or (651) 490-2860 International: 001 651 490 2860 E-mail Address:...
C H A P T E R 1 Introduction This manual contains the cleaning, troubleshooting and repair procedures ® for AeroTrak Handheld 9303 and Remote Airborne Particle Counters. N O T I C E All calibration process steps for As Found Verification and As Left ®...
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C H A P T E R 2 General Maintenance– M o d e l 9 3 0 3 This chapter explains how to disassemble the 9303 for general maintenance and/or repair. Remove 9303 power to prevent damage to the unit components. The Model 9303 contains the following parts:...
B a t t e r y R e p l a c e m e n t 1. Loosen screw (counter- clockwise) on battery cover. 2. Lift cover off and remove battery from the Model 9303. ® AeroTrak Handheld and Remote Airborne Particle Counters...
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3. Disconnect battery from the Model 9303 by pressing the locking clip on the battery side and pulling the connectors apart. 4. Plug in the new battery (P/N 700019 Model 9303 Battery Pack Replacement) and insert it back into the Model 9303.
O p e n i n g t h e C a s e 1. Remove battery from the Model 9303. See Battery Replacement. 2. Remove the four 2-mm socket-head cap screws holding the case together. 3. Gently separate the two halves enough to be able to unplug the touch pad cable from the main...
I n l e t R e p l a c e m e n t Replace Optics block O-ring if is worn out or cracked. On the new design of the block and Inlet, the O-ring is now located on the Inlet, not in the block.
P u m p a n d F i l t e r R e p l a c e m e n t 1. Open the case (see Opening the Case). 2. Remove display (see Display Replacement). 3. Remove main board (see Main Board Removal and...
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10. Attach tie wrap for filter. Leave enough space for filter. 11. Insert filter through tie wrap, tighten tie wrap and cut excess tie wrap. 12. Insert Inlet Nozzle through case opening. 13. Route pump filter tube under detector board and over the inlet nozzle. 14.
15. Secure the assembly with screws. 16. Verify pump orientation. Verify Pump Orientation 17. Follow the assembly steps in Main Board Removal and Install Display Replacement sections to reassemble unit. 18. Verify unit works as expected. D i s p l a y R e p l a c e m e n t 1.
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3. Flip the display over and rest it on the pump foam block. C A U T I O N The electronic circuits within this instrument are susceptible to electro- static discharge (ESD) damage. Use ESD precautions to avoid damage. •...
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5. Remove the display. 6. Use the display from service kit 9303 Display (S7000003). Install new display using the following steps: a. Open the display connector as shown in step 4 above. Insert display cable and close the connector. b. Snap the display on to the three standoffs (shown in step 2).
O p t i c s B l o c k C l e a n i n g To clean the Optics Block, you will have to remove it, follow cleaning procedure and then reinstall it. Optics Block Removal 1.
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4. Lift the bottom (side towards pump) of the optics block assembly enough to get access to the silicon tube connecting the pump to the optics block. Use a needle-nose plier and pull the tube off the optics block. C A U T I O N The electronic circuits within this instrument are susceptible to electro-static discharge (ESD) damage.
5. Remove the optics block from the Model 9303 housing by carefully lifting the bottom side out first until the inlet tube clears the case. Once the inlet tube clears, remove the entire block from the case. C A U T I O N The electronic circuits within this instrument are susceptible to electro-static discharge (ESD) damage.
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2. Thread the two screws you removed into the two threaded holes in the backside of the mirror. Use a flat blade screw driver, inserted under the screw head and carefully pry up on each one to remove mirror from optics block (mirror removal tool S7000150 can also be used).
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7. Re-install mirror into optics block and fasten it back down with the two Phillips head screws. 8. Remove the Phillips head screw holding the laser beam dump in place. 9. Thread the screw you removed into one of the threaded holes in the beam block.
Optics Block Installation To reinstall the optics block after removal or cleaning, follow these steps: 1. Insert Inlet Nozzle through case opening. 2. Verify pump tube is routed under detector board, is not pinched, and is over the inlet nozzle. Insert Inlet nozzle through case opening Verify pump tube is...
M a i n B o a r d R e m o v a l a n d I n s t a l l 1. Open the case (see Opening the Case) and remove display (see Display Replacement). 2.
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3. Unplug cable connections from J1, J3, J7, and J10. ® 2-18 AeroTrak Handheld and Remote Airborne Particle Counters...
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4. Remove main board from the Model 9303. 5. Plug cable connections in to J1, J3, J7, and J10 (see step 3 above). 6. Connect the display and keypad. Keep case open. 7. Power on the unit. General Maintenance–Model 9303 2-19...
L a s e r R e p l a c e m e n t C A U T I O N Laser replacement needs to be done in an ESD controlled environment with a minimum of one ESD table mat and a wrist strap connected to the installer.
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3. Remove the beam block from the optics block. 4. Remove the Phillips head screw holding the beam block in place and pull the beam block straight out of the optics assembly. C A U T I O N The electronic circuits within this instrument are susceptible to electro-static discharge (ESD) damage.
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6. Connect DVM across TP2 & TP5 on detector board. Set DVM to volts DC. This will be used to measure the laser current (voltage across a 1 ohm resistor). Example: 0.075 volts = 75 mA. 7. Turn the potentiometer on the detector board counterclockwise approx.
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9. Pull the laser board away from the optics block and fold it back to expose the laser diode. Use a needle-nosed plier to grab the laser diode and gently pull the laser diode out of the sockets on the laser board.
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12. Apply power to the unit. Adjust potentiometer on detector board until you have a reading of 0.075 volts on the DVM. Verify that you have laser power by looking at the alignment target and seeing a red spot. 13. Align the laser to the center cross hair of the alignment target by moving the laser board side-to-side/up-and-down.
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15. Adjust the potentiometer until the power meter reads the power listed below ±0.5 mW at the beam dump. 40 mW if using Melles Griot laser power meter 38 mW if using Newport laser power meter Adjust potentiometer for changing laser power Adjust potentiometer for changing laser power 16.
D e t e c t o r B o a r d R e p l a c e m e n t 1. Follow the instructions in the disassembly section and remove the optics block from the Model 9303. 2.
L i t h i u m C o i n B a t t e r y R e m o v a l a n d I n s t a l l 1. Open the case (see Opening Case) and remove display (see...
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C H A P T E R 3 General Maintenance – M o d e l s 7 2 0 1 , 7 3 0 1 , 7 3 1 0 , 7 5 0 1 , 7 5 1 0 This section explains how to disassemble the units for general maintenance and/or repair.
A remote particle counter (Models 7201, 7301, 7310, 7501, and 7510) is composed of the following parts: C l e a n I n l e t N o z z l e a f t e r C a l i b r a t i o n Swab Selection Models Nozzle (new)
3. Wet swab with Isopropyl alcohol. 4. Remove excess alcohol from swab (using method that works best for you). 5. Orient wide part of swab parallel with back of unit and clean the entire interior length of Remote Particle Counter’s “inlet nozzle.”...
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Inlet Removal If inlet is damaged, replace it with the correct model’s inlet service kit. On the new design of the block and Inlet, the O-ring is now located on the Inlet, not in the block. If you have a new design, use O-ring 1.5 x 10 mm for inlet O-ring.
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Install the New Inlet General Maintenance–Models 7201, 7301, 7310, 7501, 7510...
Optics Block Cleaning Removal To remove the optics block from the Remote Particle Counter: Remove 3 screws securing the optical block SCR M3 x .5 x 6 mm Flat Head PHH SS Unplug Cables ® AeroTrak Handheld and Remote Airborne Particle Counters...
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Remove the Optical Block from the Body of the Unit Unplug Cable Remove the Outlet General Maintenance–Models 7201, 7301, 7310, 7501, 7510...
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Remove Mirror from the Optics Block Remove the 2 screws securing the mirror to the Optical Block. SCR M3 x 4 PAN HD PHH ZI STL Attach the screws to the mirror to remove it from the laser assembly (Mirror Removal Tool S7000150 can also be used.) 1.
R e p l a c i n g t h e L a s e r A s s e m b l y The laser assembly should be replaced to correct the laser current status error. The steps below show how to replace the laser assembly in the instrument.
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1. Follow the disassembly instructions to remove the optics block from the chassis. 2. Reconnect the main board to the optics block along with the keypad to the main board. This will allow you to power up the laser for setup. DO NOT apply power to the unit at this time.
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6. Turn the potentiometer on the detector board counterclockwise approximately five (5) turns. 7. Remove the two Phillips head screws holding the laser board in place. 8. Pull the laser board away from the optics block and fold it back to expose the laser diode.
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9. Remove laser diode from service kit. Install the new laser with plastic spacer into the laser board. 10. Position the laser/laser board assembly back into the optics block and re-attach with the two screws. Leave the screws loose for alignment later.
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14. Adjust the potentiometer until the power meter reads. Refer to chart below for value ±0.5 mW at the beam dump. Laser Power: Laser Power: Model Melles Griot Newport 7201-01F, -02F, -03F, -04F Large 50 mW 47 mW 7201-01F, -02F, -03F, -04F* Large 45 mW 42 mW 7301-01, -01F...
To Reinstall the Outlet Insert O-ring if needed Ring Buna 1 x 8 mm DUR 70 Flush side of Flush side of Orifice .0230” .156” orifice is up orifice is up OD .125 L 0.1 CFM Insert orifice into nozzle NOZ-OUT w taps 7201 w 2.7 L/min cool flw Install screws...
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Part Number Description S7000139 Outlet Remote 7201F Kit (New Design) S7000142 Outlet Remotes 7301, 7501 Kit (New Design) S7000143 Outlet Remotes 7510 Kit (New Design) S7000144 Outlet Remote 7310F, 7510F Kit (New Design) S7000162 Outlet Remotes 7301F, 7501F Kit (New Design) Plug Cable Plug Cable Insert Optical Block into Unit Body...
Install the 3 screws to secure the optical block Install the 3 screws to secure the optical block SCR M3 x .5 x 6 mm Flat Head PHH SS SCR M3 x .5 x 6 mm Flat Head PHH SS Detector Board Replacement 1.
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C A U T I O N The electronic circuits within this instrument are susceptible to electro-static discharge (ESD) damage. Use ESD precautions to avoid damage. • Use only a table top with a grounded conducting surface. • Wear a grounded, static-discharging wrist strap. 4.
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C H A P T E R 4 General Maintenance – M o d e l 7 3 0 1 - P This section explains how to disassemble the 7301-P for general maintenance and/or repair. Remove 7301-P power to prevent damage to the unit components.
R e p l a c i n g t h e I n t e r n a l F i l t e r s The internal filters should be replaced on the schedule documented in the maintenance schedule (6003662). The steps below show how to replace the two internal filters in the instrument.
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2. Orient the unit so that you have access to both the filters. 3. DO NOT remove all the tubing connected to the filters simultaneously. Instead disconnect the tubing for the first filter. Check if the tubing is dirty. If so, replace the tubing.
R e p l a c i n g t h e I n t e r n a l P u m p The internal pump can be replaced to correct flow errors. The steps below show how to replace the internal pump in the instrument. Replacement part needed for a 12 volt pump is one (1) 12V...
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2. Disconnect the two HEPA filters by cutting the two tie wraps holding the filters down. 3. Remove the Phillips head screws that hold the pump and HEPA filter assembly. General Maintenance–Model 7301-P...
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4. Disconnect the power cable to the optics sensor. 5. Flip over the assembly to gain access to the outlet of the optics chamber. ® AeroTrak Handheld and Remote Airborne Particle Counters...
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6. Disconnect the power cable between the main board and the optics unit. General Maintenance–Model 7301-P...
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7. Disconnect the tubing that goes between the outlet of the chamber to the inlet of the pump. 8. Replace the filter assembly and the HEPA filters with a new assembly. ® AeroTrak Handheld and Remote Airborne Particle Counters...
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9. Start by removing the screws holding the pump. 10. Remove the entire assembly of the pump and filters without disconnecting any tubing. General Maintenance–Model 7301-P...
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11. Take the new assembly of the pump and filters and mount them to the frame that houses the pump and the filters. Start by first tie- wrapping the filters as shown. 12. Next connect the pump suction side (inlet) to the outlet of the optics chamber as shown in the...
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13. Note the direction of connections for the pressure transducer between the optics outlet and the main board. 14. Reassemble unit in reverse order. General Maintenance–Model 7301-P 4-11...
R e m o v a l o f F l o w C o n t r o l B o a r d Follow these instructions to remove and install the Flow Control board. Replacement part needed for a Flow Control board is one (1) Flow Control board kit (S7000176).
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5. Remove board and install new one. 6. Connect power wires to terminals. The wire with the white dashes will go to the +12V terminal. 7. Connect all the other connections. 8. Re-assemble unit and calibrate. General Maintenance–Model 7301-P 4-13...
R e m o v a l o f O p t i c s B l o c k f o r C l e a n i n g o r L a s e r R e p l a c e m e n t Follow these instructions to remove optics block prior to cleaning or laser replacement.
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3. Disconnect all cables between the optics chamber and the main board as shown in the photo below. 4. The optics chamber can now be accessed for cleaning and replacing the mirror/laser diode. At this point, the optics chamber can be completely separated from the main board.
I n l e t C l e a n i n g The inlet should be cleaned on the schedule documented in the maintenance schedule (6003662) or to correct a laser scatter status error. The steps to clean the inlet are shown below. 1.
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2. Thread the two screws you removed into the two threaded holes in the backside of the mirror. Use a flat blade screw driver, inserted under the screw head and carefully pry up on each one to remove mirror from optics block. Mirror removal tool (S7000150) can also be used.
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7. Re-install mirror into optics block and fasten it back down with the two Phillips head screws. 8. Remove the Phillips head screw holding the laser beam dump in place. 9. Thread the screw you removed into one of the threaded holes in the beam block.
R e p l a c i n g t h e L a s e r A s s e m b l y The laser assembly should be replaced to correct the laser current status error. The steps below show how to replace the laser assembly in the instrument.
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5. Connect DVM across TP2 & TP5 on detector board. Set DVM to volts DC. This will be used to measure the laser current (voltage across a 1 ohm resistor). Example: 0.075 volts = 75 mA. 6. Turn the potentiometer on the detector board counterclockwise approximately five (5) turns.
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8. Pull the laser board away from the optics block and fold it back to expose the laser diode. Use a needle nosed pliers to grab the laser diode and gently pull the laser diode out of the sockets on the laser board.
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11. Apply power to the unit. Adjust potentiometer on detector board until you have a reading of 0.075 volts on the DVM. Verify that you have laser power by looking at the alignment target and seeing a red spot. 12. Align the laser to the center cross hair of the alignment target by moving the laser board side-to-side/up-and-down.
14. Adjust the potentiometer until the power meter reads the power listed below ±0.5mW at the beam dump. 35 mW if using Melles Griot laser power meter 33 mW if using Newport laser power meter 15. Turn power off and re-assemble beam block to optics assembly. 16.
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C A U T I O N The electronic circuits within this instrument are susceptible to electro-static discharge (ESD) damage. Use ESD precautions to avoid damage. • Use only a table top with a grounded conducting surface. • Wear a grounded, static-discharging wrist strap. 4.
C H A P T E R 5 Service Kits for Replacement Components Each contamination control instrument has a few field-replaceable units. Each service kit below is assembled to replace the main component (example pump) and associated components (connecting tubes, foam, and pump power input).
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Part Number Description ® S7000007 9303 Case Kit (TSI (1) Case, Top ® (1) TSI Logo (1) Key Pad (1) Model Label (1) Battery Foam (1) Screw (battery cover) S7000008 9303 Case Kit (BioTest)(MK) (1) Case, Top (1) BioTest Logo (1) Key Pad (1) BioTest Model Label (1) Battery Foam...
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Part Number Description S7000039 Inlet Remotes 7301, 7501, 7301F, 7501F Kit (1) Nozzle, Inlet, 0.1 CFM CC OPC S7000040 Outlet Remote 7301F, 7501F Kit (1) Nozzle, Outlet, Pressure Taps CC OPC S7000041 Outlet Remotes 7301, 7501 Kit (1) Nozzle, Outlet CC OPC S7000043 Outlet Remotes 7510 Kit (1) Nozzle, Outlet CC OPC...
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Part Number Description S7000160 7301-P Cable Kit (5) 6003735 Cable tie, 10-3/4 Long, 60 lb (5) 1303824 CBL ASSY 2.1 mm PWR RTANG (5) 6003430 CBL CAT5e 1-ft Patch Cable Yellow (5) 6003427 CBL RJ11 (6 x 4) to RJ11 (6x4) 1 ft (5) 6002144 CBL ASSY 1.5"...
C H A P T E R 6 Troubleshooting Symptom Possible Cause Corrective Action Display jittery or not Contrast too low. Open unit and adjust potentiometer on working (Model 9303) main board to modify display contrast. Display Replacement. Inspect display cable for cuts or exposed Unseated cables.
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Symptom Possible Cause Corrective Action Wrench symbol for laser Incorrect scatter voltage This is likely due to high light scatter in the errors chamber. Clean optics (mirror and beam dump) if dirty See Optics Block Cleaning. Cable between laser board and photo detector board is disconnected or loose or bad.
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Symptom Possible Cause Corrective Action Counts are too low Internal optics have become dirty Optics Block Cleaning for cleaning details Instrument has contamination on the optics Clean instrument. See Optics Block due to condensation or excessive loading Cleaning. Incorrect flow rate Tubing from the pump inlet is not connected to the outlet nozzle or tubing is leaking (Model 9303).
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Stirling Road Cressex Business Park High Wycombe, Bucks HP12 3ST UNITED KINGDOM Telephone: +44 (0) 149 4 459200 E-mail: tsiuk@tsi.com TSI Instruments Singapore Pte Ltd 150 Kampong Ampat #05-05 KA Centre SINGAPORE 368324 Telephone: +65 6595-6388 Fax: +65 6595-6399 E-mail:...
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BP 100 Technopôle de Château-Gombert 13382 Marseille cedex 13 FRANCE Telephone: +33 (0) 1 41 19 21 99 E-mail: tsifrance@tsi.com TSI Instruments Singapore Pte Ltd 150 Kampong Ampat #05-05 KA Centre SINGAPORE 368324 Telephone: +65 6595-6388 Fax: +65 6595-6399 E-mail: tsi-singapore@tsi.com...
R e t u r n i n g f o r S e r v i c e and complete the on-line “Service Visit our website at tsi.com\service Request” form or call TSI ® at 1-800-680-1220 (USA), (651) 490-2860, or 001 651 490-2860 (International) for specific return instructions.
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A P P E N D I X A Webpage M a i n W e b p a g e The main webpage can be used to read the basic instrument information, including the latest particle count measurement.
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Section Item Description Serial Number Serial Number of the instrument Instrument Location Location string that can be set by user Unit Address Address that can be set by user Firmware Version Firmware versions on the main computer board MAC Address Unique TCPIC identifier IP Address Current IP address of the instrument...
T e c h W e b p a g e The tech webpage is used to configure the instrument. It is accessed by clicking on the Admin link on the main page and entering a password. The password’s factory default is “admin”. Appendix A...
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Section Item Description Tech Password Used to change the password that is required to access the tech webpage. Date/Time Used to set the internal date and time of the instrument. This date and time will be stamped to each particle record. Set Location Use to enter an ASCII string to describe the location of the instrument.
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TSI Incorporated – Visit our website www.tsi.com for more information. Tel: +1 800 680 1220 India Tel: +91 80 67877200 Tel: +44 149 4 459200 China Tel: +86 10 8219 7688 France Tel: +33 1 41 19 21 99 Singapore Tel: +65 6595 6388 Germany Tel: +49 241 523030...
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